Testchip design for process analysis in sub-micron DRAM fabrication

ABSTRACT

Integrated circuit chips having large regions of different device density and topography are susceptible to local processing variations which give rise to systematic failures affecting some circuit regions and not others. Over-simplified test structures cannot signal these failures during processing. Memory chips have large regions of storage cell arrays serviced by sizeable peripheral regions consisting of logic circuits. The device density and configuration in each of these regions on the chip are quite different. During processing steps these regions present differently to the process agents such as chemical etchants and plasmas producing in local variations of processing rates occur which result in systematic under processing in one region or over processing in another. Memory chips are particularly prone to such variations and also lend themselves well to the design of product specific test structures for flagging these aberrations. Several test structures are described which are formed from regions of the integrated circuit product itself. The structures are designed to monitor specific process steps where such local variations occur. The invention teaches the use of product specific test structures for process monitoring of sub-micron DRAM integrated circuits. The structures described are portions of the cell array outfitted with test probe pads and are capable of measuring opens and shorts in wordlines and bitlines. Another structure comprises a testable string of bitline contacts.

This is a division of patent application Ser. No. 08/851,596 filing dateMay 5, 1997, Testchip Design For Process Analysis In Sub-Micron DramFabrication, assigned to the same assignee as the present invention, nowU.S. Pat. No. 5,872,018.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention relates to monitoring and diagnostics of line processesused for the manufacture of semiconductor devices and more particularlyto the design of product specific test chips.

(2) Description of Prior Art

Integrated circuits(ICs) are manufactured by first forming discretesemiconductor devices within the surface of silicon wafers. Amulti-level metallurgical interconnection network is then formed overthe devices contacting their active elements and wiring them together tocreate the desired circuits. The wiring layers are formed by firstdepositing an insulating layer over the discrete devices, patterning andetching contact openings into this layer, and then depositing conductivematerial into these openings. A conductive layer is then applied overthe insulating layer which is then patterned and etched to form wiringinterconnections between the device contacts thereby creating a firstlevel of basic circuitry. These circuits are then further interconnectedby utilizing additional wiring levels laid out over additionalinsulating layers with via pass throughs.

Depending upon the complexity of the overall integrated circuit, one ortwo levels of patterned polysilicon conductors and two or more levels ofmetallurgy are required to form the necessary interconnections and todirect the wiring to pads which make the external connections for thecompleted chip. These patterns are formed by photolithographic maskingtechniques accompanied by reactive ion etching(RIE). The formation ofsuch patterns invariably results in topographic features which effectthe integrity of subsequently deposited layers, in particular when theselayers are deposited by directional techniques such as sputtering orvacuum evaporation. Metal layers are typically deposited by suchtechniques.

Topographic features cause shadowing which results in poor edge coverageby the metal layer. When wiring patterns are subsequently etched inthese layers, the regions of poor edge coverage are open or resistive,and likely to cause failure. Although various steps are taken to smoothout surface non-planarities, such as chemical mechanical polishing andthermally flowing of insulative glass layers, edge coverage problemsstill occur. As device geometries continue to shrink and depositedlayers become thinner, process control must include testing integrity ofthese conductors.

In addition to the shadowing effects caused by topographic features,variations in device density over the surface of the wafer can causeprocessing variations. Differences in device density can cause localvariations of processing rates which can cause some regions to be underprocessed and others to be over processed.

Whereas an integrated circuit chip may undergo a hundred or morediscrete processing steps from starting wafer to finished chip,electrical testing of the chip itself is impossible until the chip iscompleted. Then only functionality tests may be done.

In order to monitor the step by step processing, parametric and defecttest structures are used which are process step specific and can betested between processing steps. During masterslice or front end ofline(FEOL) processing, only parametric structures are used since actualdevices are not yet formed. During the personalization or back end ofline(BEOL) processing when the metal wiring levels are formed, testablestructures may be conveniently formed and used to statistically evaluatefind defects caused by particulate contamination. Processing steps suchas photolithographic operations and plasma deposition and etching areparticularly prone to defects caused by random particulate contaminationwhich produces failure modes such as metal-to-metal shorts and opens.Interlevel shorts, and highly resistive or open vias and contacts.

Test structures for monitoring FEOL quantities such as implantresistivities, junction parameters and the like do not require largeareas on the semiconductor wafer. They are frequently built into the sawkerf regions and are tested with probes during the FEOL processing.

Unlike parametric structures, the test structures required to examinethe yield impact of random defect induced failure modes encountered inBEOL require larger semiconductor surface areas in order to givemeaningful statistical information. Specifically, the structures whichmeasure defect failure mechanisms must have critical areas comparable tothose found on product chips. Thus, for example, a test structure whichis designed to measure metal-to-metal shorts, must not only have anareas of adjacent metal lines comparable to such areas in the productbut also there must be an adequate number of such structures present inorder to provide statistically meaningful data.

In order to cope with these large area requirements a number of specialdie locations on each wafer may be allocated to these test structures.These are referred to as yield management test sites or simply as testchips. Clearly, their presence requires the sacrifice of valuable waferarea and they are either formed on separate test wafers inserted intojobs or they may occupy 3 to 6 chip locations on each product wafer.Statistical evaluations are made not at the wafer level but at the joblevel where an adequate sample size may be had.

The test structures themselves typically comprise mazes of serpentinemetal or polysilicon lines, frequently with multiple taps, whichcorrespond in width and spacing to lines on the product IC. These widthsand spacings should generally reflect the dimensions found in the ICcounterpart. The ends and taps of these lines are brought to probe padswhich can be tested immediately after a metallization pattern is formed.The metal line mazes on a single metal level are tested for opens andshorts.

Test structures of various types for determining defect induced failurehave been described. Comeau U.S. Pat. No. 5,329,228 describes a testchip which utilizes a transmission gate matrix which, when tested,provides information regarding a number of discrete failure types whichcan be attributed to certain processing steps. The structure can only betested when the processing is complete. The process specific informationsuch a test chip provides is only useful to point out serious processdeviations to which much more timely alerts should be given. It is notcost effective to discover an process problem occurring at an early stepwith a test chip that must travel through the entire process.

Hsu U.S. Pat. No. 5,468,541 describes a test chip which looks atde-lamination of layers. This chip also engages the complete process andis then subjected to environmental stressing in order to discoverprocessing problems. This test chip like that of Comeau are primaryuseful for evaluating chip and process design rather than for real-timeprocess monitoring.

Integrated circuit chips contain various types of functional circuitry.The density if devices and wiring for each type can be quite different.This is particularly true for Dynamic-Random-Access-Memory(DRAM) wherethe density of wiring over the array portion of the chip is considerabledifferent than that over the support circuitry. These variations affectsome levels much more so than others. In addition the widths andspacings of the wiring over the array regions are different than thoseof the support circuits. Consequently the susceptibility of the arraycircuits to defect induced failures is different than that of thesupport circuits.

Shown in FIG. 1 is an example of a simple maze test structure formed ona wafer 10 from in a DRAM manufacturing process line. The maze ispatterned in a first polysilicon layer which forms the gate electrodesof the product. The structure has two interlaced serpentine lines havinga constant width and having probe pads at both ends of each line. Forclarity, test line 101 is hatched differently than test line 102. Probepads 103 and 104 are located at the ends of test line 101 and probe pads105 an 106 are at the ends of test line 102. Optional pads 107 and 108to taps are also shown. By themselves, the lines may be tested for opensand shorts. In this example, additional testing may be done to qualify agate oxide which is formed beneath polysilicon lines 101 and 102 in theform of stripes 9 located between regions of field oxide 12. FIG. 2 is across section showing a polysilicon line 16 traversing one such gateoxide stripes 9.

By applying test probes between the polysilicon test lines 101 or 102and the wafer 10, the integrity of the gate oxide 14 may also bedetermined immediately after the polysilicon 16 is patterned therebyproviding timely data on, for example, gate oxide breakdown voltage.

Maze test structures of the type shown in FIG. 1, by virtue of theirserpentine configuration, have a high critical area, and therefore ahigh sensitivity for random defects. By variation of the line widths andspacings, a size distribution of the random defects may be obtained.This information is valuable, not only for process development but forcircuit design guidelines as well.

Although test structures such as the one shown in FIG. 1 and FIG. 2 canprovide valuable data, their simplicity often belies more intricate andcomplex electrical consequences occurring in the product IC. Thesemisrepresentations by the simple test structures become more pronouncedas pattern and device dimensions shrink to sub-micron levels.

The parametric test structures, probed during FEOL, are essential inproviding timely warning of tool malfunctions and other processirregularities, thereby permitting scrapping of out of spec wafers earlyon in the processing cycle. The serpentine, maze, and chain structureswhich can be tested after each metallization level, likewise providetimely information pointing out contaminated tools, etchant solutionsand the like. The utilization of this type of process monitoring isessential to maintaining an efficient, high yielding, and cost effectivemanufacturing line.

There are, however, other process or design induced features whichresult in ultimate failure of integrated circuits. These may beclassified as systematic or non-random failure mechanisms. Perhaps thesimplest and easiest to comprehend systematic failure is the mask defectwhich will consistently cause a device failure and will not be flaggedby the conventional test sites. Other types of systematic failures whichmanifest themselves particularly in present day ICs having varyingdegrees of circuit density and topology, cannot be properly detected bythe simple conventional test sites.

Memory chips, for example, have large regions which consist of storagecell arrays. FIG. 2 is a plan view of the layout of a memory chip 120.The cell array 122 is serviced by sizeable peripheral logic circuits 124known as address decoders. The device density and configuration in eachof these regions on the chip are quite different. Line spacings andshapes as well as the surface topography are also different. During manytypes of processing steps these regions present differently to theprocess agents such as chemical etchants, plasmas, and the like.Consequently, local variations of processing rates occur which canresult in systematic under processing in one region and over processingin another.

Yanagisawa et.al. U.S. Pat. No. 5,506,804 describes numerous testingprocedures that may be done on a completed memory integrated circuit.This type of testing can reveal systematic defects in certain regions ofthe IC but in order to pinpoint process or design sources of thesefailures can require lengthy and costly physical unlayering of thefailed chips. Process or design corrections could then be made. The timeperiod between initial occurrence and repair of such defects could beenormous.

To find these failures and make process or design corrections in atimely fashion, test structures must be used which closely resemble aproduct IC in device density, pattern, and topology. For example, onemay consider the process of etching a metal pattern using RIE. Theetching time required to completely etch the pattern in a sparselypopulated region of the IC chip may be considerably different from thatin a region having a high density of metal lines. Such variations infeature density and topology are commonplace in the manufacture of DRAMswhere the density and topology of features in the peripheral supportcircuitry is significantly different from that in the array area. Thus,while some regions of the chip may be properly etched, others areas mayhave residual pockets of metal which may produce shorts.

The causes of these pattern sensitive effects are varied. In instanceswhere chemical processing is involved they are likely to be caused by aloading effect wherein reactant depletion occurs or topological featuresalter reactant accessibility. The effect of regions of different featuredensity and topology on processing characteristics is sometimes referredto as the global proximity effect. Simple parametric or maze type defectdensity structures described hereinbefore are not adequate for revealingsuch systematic problems.

The test structures required to address failure modes such as caused bythe global proximity effect, must therefore resemble the product ingreat detail while at the same time be capable of measurement during thewafer process cycle. These test structures must be product specific and,at best, a single set of test structures could be associated with aclass of closely related products.

Fortunately the ICs which are most affected by systematic processingproblems are the ones which lend themselves best to the use of productspecific test sites to address them. This invention deals with the useof product specific test chips in the manufacture of high densitymemories.

A portion of a current cell design for a stacked capacitor(STC) DRAMhaving diagonal active areas and a capacitor design similar to that ofDennison U.S. Pat. No. 5,292,677 is shown in cross section by FIG. 3 andin a top view by FIG. 4.

Referring first to FIG. 3, two storage capacitors 36, of a tubulardesign, are shown formed on a silicon wafer 10. The lower, storageplates 24 contact the source diffusions 18 of two adjacent metal oxidefield effect transistors (MOSFET)s whose gates 16 comprise polysiliconwordlines. The bitline 40 connects to the common drain 20 of the twoMOSFETs. The polysilicon wordlines 16 located over field oxide regions12 service other MOSFETS located in the array above and below the planeof the page. Inter-polysilicon-insulator (IPO) layers 14 and 22 supportand insulate the large area portions of the capacitors 36 above thewordline/bitline array. The capacitor dielectric, typically, a compositelayer of SIO₂ /Si₃ N₄ /SiO₂ (ONO) 25, is covered by the upper cell plate26 which spans a plurality of cells.

An inter-level-dielectric (ILD) layer 28 insulates the upper cell plate26 from a subsequently deposited metal layer, which becomes the firstlevel of wiring for the DRAM circuits. Contacts, formed through openingsin the ILD connect it to the circuit elements. Most of these contactsare directed to the peripheral circuitry of the DRAM.

Referring now to FIG. 4, a top view of the DRAM cell array is shown. Thecross section of FIG. 4 through the line 3-3' is shown in FIG. 3. Theactive regions 11, are diagonally disposed to the perpendicularwordlines 16 and bitlines 40. The contact regions of the bitlines 17 andof the capacitor storage plates 19 to the active regions are shown.

This invention teaches the use of structures which closely resemble thecell array of a DRAM IC and can be tested during processing. Thestructures reflect the complexity and topology of the product cell arrayto signal systematic process aberrations as well as design defects whichcause device failures.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a method for designingproduct specific test structures which can be used for real-time processmonitoring in the manufacture of sub-micron DRAM integrated circuits.

It is another object of this invention to provide a method for designingproduct specific test structures which can relate process and designtolerance information with regard to systematic failure mechanisms.

It is yet another object of this invention to provide designs forproduct specific test structures which can be tested in a timely fashionduring processing, to detect and evaluate systematic failure modes,thereby permitting rapid turn around times for correction, either ofprocess or of design.

It is yet another object of this invention to provide a method fordesigning test structures which can provide a database for developingproduct specific design ground rules.

These objects are accomplished by the use of an assembly of probetestable IC structures on a test chip, said structures comprising, forthe most part, exact replicas of product functional regions. Thetestable structures may be formed from the product IC itself byproviding the various functional regions with probable test pads or theymay be designed separately on a test chip. Of primary importance is thatthe test structures have the same topography and component density asthe product IC and that the layout of the test chip closely resemblesthat of the product with respect to circuit design, density andtopography.

A testchip used to provide a database for design ground rules andprocess tolerance evaluation contains a groups several structures of thesame type, each with design dimensions varying about a target valuethereby creating a design window. Using the hereinbefore mentionedexample of etch variation of polysilicon in different types of circuits,it may be found that by changing the minimum design ground rule for onecircuit type will cancel or substantially reduce the occurrence ofsystematic failures cause by these etch variations.

The test chip structures represent all the fundamental circuit groupsfound on the product IC. The invention used a test chip for a DRAM IC asan example. The test chip then contains cell array structures, as wellas structures of the various peripheral circuit modules such as addressdecoder circuits and sense amplifiers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a serpentine test structure.

FIG. 2 is a plan view of a memory integrated circuit chip.

FIG. 3 is a cross sectional view of a portion of a stacked capacitorDRAM cell array having a buried bitline.

FIG. 4 is a top view of a portion of a stacked capacitor DRAM cell arrayhaving a buried bitline.

FIG. 5A is a cross sectional view of a portion of a first embodiment ofthis invention showing in-process testable wordlines after theirformation.

FIG. 5B is a top view of a portion of a first embodiment of thisinvention showing in-process testable word lines after their formation.

FIG. 6A is a cross sectional view of a portion of a second embodiment ofthis invention showing in-process testable bitlines after theirformation.

FIG. 6B is a top view of a portion of a second embodiment of thisinvention showing in-process testable bitlines after their formation.

FIG. 7A is a cross sectional view of a portion of a third embodiment ofthis invention after a first metallization pattern is formed.

FIG. 7B is a cross sectional view of a portion of a third embodiment ofthis invention showing a bitline contact to a metal wiring pattern.

FIG. 7C is a cross sectional view of a portion of a third embodiment ofthis invention showing a wordline contact to a metal wiring pattern.

FIG. 7D is a top view of a portion of a third embodiment of thisinvention showing a completed DRAM cell array probe testable after firstmetal wiring.

FIG. 8A is a top view of a portion of a fourth embodiment of thisinvention showing a contact string for testing bitline contactintegrity.

FIG. 8B is a cross sectional view of a portion of a fourth embodiment ofthis invention showing a contact string for testing bitline contactintegrity.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Accordingly, in the embodiments of this invention, a p-type <100>oriented silicon substrate(wafer) is provided. The embodiments use, asan example, an integrated circuit process for the manufacture of adiagonal active stacked-capacitor with a highly packed storagenode(DASH) cell DRAM. It is to be understood that the application ofthis invention is not confined to DRAM integrated circuits but could beapplied to any semiconductor fabrication process.

The embodiments described are test structures having the features andtopology of the cell array. It is to be understood that correspondingtest structures from other regions of the IC may be simultaneouslyformed and tested. These test structures represent the variousperipheral circuit groups, having different features and topology, foundon the IC chip. It is also to be understood that the test structures ofthese embodiments are formed in concert with the formation of productintegrated circuit chips, preferably on the same silicon wafers. Thusthey undergo identical processing and handling.

Referring to the cross section in FIG. 5A the formation of a firstembodiment of this invention is described. A p-doped <100> orientedmonocrystalline silicon wafer 10 is provided. Field isolation regions 12are formed by well known locallized oxidation techniques defining aactive region 11. A gate oxide 13 is formed over the active regions andpolysilicon wordlines 16 are patterned.

Referring now to FIG. 5B there is shown a top view of a portion of thefirst embodiment of this invention. The cross section shown in FIG. 5Ais indicated by the line 5A-5A'. This is the cell array portion of atest structure intended to be measured for systematic shorts betweenpolysilicon word lines caused by, for example, insufficient etchingduring the polysilicon RIE. The embodiment is formed on the test chipusing the identical process flow afforded to the corresponding productIC. The test chip may be formed on a test wafer or it may be formed on adesignated chip site of a product IC wafer. The region 30 is identicalto a region of the cell array of the product IC containing the siliconactive areas 11 within the field oxide isolation 12.

To complete the design of the test structure, several wordlines 16 areterminated at probe contact pads 32 formed in the periphery of the teststructure. Probe pads 32 are formed at both ends of each selectedwordline. The high density of wordlines in the typical cell arraystructure will not permit the termination of every wordline on a probepad. Therefore several selected groups of 2 to 4 mutually adjacentwordlines form the testable elements of the structure. At this point inthe processing, the structure may be tested for shorts between adjacentwordlines and for wordline continuity by applying test probes to thecontact pads 32.

Testing the cell array structure alone will indicate the presence orabsence of shorts and opens. However, the causes of the failures will beindicated when similar tests are made on maze type structures of thetype shown in FIG. 1. Shorts and opens tests on the maze structuresindicate the presence of random defects. If the maze structures do notindicate shorts caused by random defects, and the test structurecomprising the first embodiment has multiple shorts, a systematicprocess under etch of the polysilicon is indicated. Similarly, a highoccurrence of word line discontinuities in the absence of excessiveopens in the maze structures, indicates possible inadequate edgecoverage by the polysilicon along contours such as over field oxide.Such occurrences, however, are more likely to occur with metal linesthan with polysilicon which is deposited by a conformal process.

After testing is completed, further processing of the test chip forms asecond embodiment of this invention. Referring to the cross section inFIG. 6A the formation of a second embodiment of this invention isdescribed. The source and drain diffusions 18, 20 have been formed usingthe polysilicon gate electrodes for self-alignment. An insulative layer14 is deposited over the gate electrode structure and this layer isplanarized using chemical mechanical polishing or another planarizationmethod. Bit line contacts 19 to the diffusion 20 are formed by etchingopenings into this layer and depositing the polysilicon bitline 40 intothe contact openings. The bitlines 40 are then formed by etching apattern in a deposited polysilicon layer. In other DRAM designs,bitlines are formed after the storage capacitor. These bitlines,typically of aluminum or an aluminum alloy, require a deeper contact andmay employ the use of tungsten plugs to form the contact with thesilicon diffusion 20.

Referring now to FIG. 6B there is shown a top view of a portion of asecond embodiment of this invention after the bitlines 20 have beenformed. The cross section shown in FIG. 6A is indicated by the line6A-6A'. The bit lines connect to the diffusion 20 through contact 19.This is the cell array portion of a test structure intended to bemeasured for systematic shorts between polysilicon bit lines caused by,for example, insufficient etching during the polysilicon RIE. Theembodiment is formed on the test chip using the identical process flowafforded to the corresponding product IC. The bitlines 20 runperpendicular to the wordlines 16.

To complete the design of the second embodiment a plurality of bitlines40 are terminated at probe contact pads 42 formed in the periphery ofthe test structure. The high density of bitlines in the typical cellarray structure will not permit the termination of every bitline on aprobe pad. Therefore several selected groups of 2 to 4 adjacent bitlinesform the testable elements of the structure. At this point in theprocessing, the structure may be tested for shorts between adjacentbitlines by applying test probes to the contact pads 42.

As with the test structure of the first embodiment, testing the bitlines in the cell array structure of the second embodiment alone willindicate the presence or absence of shorts and opens. However, thecauses of the failures will be indicated when similar tests are made onmaze type structures of the type shown in FIG. 1. Shorts and opens testson the maze structures indicate the presence of random defects. If themaze structures do not indicate shorts caused by random defects, and thetest structure comprising the second embodiment has multiple shorts, asystematic process under etch of the polysilicon is indicated.

After testing of the second embodiment is completed, further processingof the test chip forms a third embodiment of this invention. Referringto the cross section in FIG. 7A the formation of a third embodiment ofthis invention is described. An insulative layer 22 is deposited overthe bitline pattern 40. Storage capacitors 36 are formed by a sequenceof processing steps well known by those familiar with the art. Thebottom storage plate 24 of each capacitor 36 contacts the silicon activearea 18 of the MOSFETs. The top plates 26 of the storage capacitors 36are connected together. An insulative layer 28 is deposited andconductive contacts 54 (FIG. 7B) and 56 (FIG. 7C) are formed to ends ofthe bitlines and wordlines respectively, in the periphery of the teststructure. An additional contact (not shown) is made to the uppercapacitor plate 26 so that functional testing of selected cells may beaccomplished. A metal layer is next deposited and patterned to formconnections 50 and 52 to the contacts.

Referring now to FIG. 7D there is shown a top view of the thirdembodiment. The cross section of FIG. 7A is denoted by the line 7A-7A'.The contact cross sections of FIG. 7B and 7C are likewise denoted by thelines 7B-7B' and 7C-7C' respectively. The metal connections to thecontacts 54 and 56 are terminated by probe pads 50 and 52 respectively.As in the first and second embodiments, the probe pad terminatedbitlines and wordlines are selected in groups of 2 to 4 adjacent units.Additional probe pads (not shown) are provided for other connectionssuch as to the capacitor top plate 26 and the substrate 10.

The test chip may now be tested again for opens and shorts as well asfor functionality of the cell array. Testing at this stage allowsscrapping to take place before chip completion, thereby savingunnecessary processing costs of defective wafers.

In a fourth embodiment of this invention a test structure for theevaluation of bitline contact integrity is described. The bitlinecontacts used in high density sub-micron DRAM cell arrays are numerous,small, and have high aspect ratios. DRAM designs which do not usepolysilicon bitlines require more complex contact formation such asevaporated metals and the use of tungsten plugs accompanied by a barriermetallurgy such as Ti/TiN. These contacts typically involve the use ofdirectional deposition processes which are non-conformal. Bitlinecontacts are therefore subjected to numerous occasions wherein minorprocess aberrations including localized process variations make themhighly susceptible to being resistive or open.

Bitline contacts, such as those used in the design of the presentembodiment, are formed early on in the process sequence. For thisreasons it is highly desirable to have a test structure which canreliably signal contact irregularities in a timely fashion, therebypermitting scrapping and avoiding costly wasted processing.

The embodiments heretofore described have not required design changeswithin the cell array. The only mask changes required were theincorporation of probe pads at the ends of the wordline and bitlinestripes. These embodiments provided for testing of line continuity aswell as inter line shorts. In a fourth embodiment, the ability to testthe integrity of bitline contacts is provided at the expense of losinghalf of the available cells in the test chip. This does not present anyproblem with regards to testing, however, since space available forprobe contacts in the periphery of the test structure allows only alimited number of elements to be tested. However, in order to formcontact strings it is necessary to include minor disruptions of topologyin the cell array.

The fourth embodiment is a contact string formed on a test chip usingthe layout of the cell array of the corresponding product DRAM IC with aminimal variation. As with the preceding embodiments, the DRAM cellarray layout lends itself well to the design and formation of structuresfor testing contact integrity. What is required for contact testing is astring of many contacts connected in series. This string is terminatedwith a probe pad at each end. Measurement of the resistance of thestring signals the presence of open or resistive contacts. In order toform a serial string of bitline contacts the bitline must be interruptedat alternate contacts and the silicon diffusion to which the contactsconnect must be used to make the string continuous.

The layout of the DASH cell DRAM includes four wordlines passing underthe bitline between each pair of bitline contacts. In order to make thediffusion continuous between these contacts. These four wordlines mustbe interrupted under the bitline in order to permit dopant to access thesilicon. In addition the field oxide must also have a channelcorresponding to the path between the two bitline contacts.

FIG. 8A is a plan view of a portion of a bitline contact string on aDASH cell DRAM test chip formed in accordance with the fourth embodimentof this invention. The interrupted word lines 60 terminate near the edgeof the active area diffusions 63 and 67. Wordlines 16 pass uninterruptedunder the bitline segments 63 and 65. As in the other embodiments thetest lines are terminated by probe pads 50 over field oxide. The seriespath followed by the contact string is better shown in FIG. 8B which isa cross section of the region in FIG. 8A denoted by 8A-8A'. Test currenttravels from one probe pad to bitline segment 61, through bitlinecontact 62, to diffusion 63, thence through contact 64, through bitlinesegment 65, through contact 66 to diffusion 67 and so on through thestring and to the other probe pad.

Electrical testing can be accomplished after the bitline is formed. Openor resistive contacts can be detected by measuring the resistance of thecontact string between the two probe pads and comparing its value to anestablished target resistance. This will vary depending upon the sizeand design of the contact string.

While this invention has been particularly shown and described withreference to the preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade without departing from the spirit and scope of the invention.

The well known DRAM configuration shown in FIG. 1 acts as the referencefor these and embodiments although the features of these embodiments areequally adaptable to other DRAM designs and configurations. The testlines or contact strings for smaller functional device regions, forexample address decoder regions, may require the stripes to be formed ina serpentine, or otherwise in a sensible meandering pattern, in order toprovide test structure size comparable to that in the corresponding IC.A key requirement for these test chip structures, however, is that theybe designed to represent the pattern shape, topography and the densityof corresponding features in the product IC. This can be accomplished ina most practical manner by using the IC design itself and makingappropriate minor modifications to allow meaningful in process testing.The teaching of this principle is intended by the embodiments of thisinvention. In general, IC designs most vulnerable to systematic processirregularities also lend themselves well to simple modification for testchip structures.

Whereas the embodiments described use polysilicon conductive stripes inthe formation of test chip structures for a DRAM, test chip structurescan also be formed utilizing metal conductive stripes as occur at levelswhere metal wiring patterns are used. The principles of design andlayout with regard to product IC taught by these embodiments should beequally followed in forming such test chips.

While the embodiments of this invention utilize a p-type siliconsubstrate, an n-type silicon substrate could also be used withoutdeparting from the concepts therein provided.

It should be further understood that the substrate conductivity type asreferred to herein does not necessarily refer to the conductivity ofwafer but could also be that of a diffused region wherein the devicesare incorporated.

What is claimed is:
 1. A structure for electrical testing during themanufacture of an integrated circuit comprising:(a) a region on asilicon substrate designated for a said structure; (b) field isolationformed in said region in a layout identical to field isolation in afunctional section of said integrated circuit; (c) semiconductivedevices formed in said region in a layout identical to said functionalsection; (d) first conductive stripes patterned over said semiconductivedevices in a layout identical to corresponding first conductive stripesin said functional section, said first conductive stripes passing,essentially parallel to each other from one side of said region to theother; and (e) means for application of test probes to a plurality ofsaid first conductive stripes.
 2. The structure of claim 1 wherein saidintegrated circuit is a DRAM and said functional section is a portion ofa cell array.
 3. The structure of claim 2 wherein said structurecontains between about 50 and 5,000 partially processed cells.
 4. Thestructure of claim 2 wherein said semiconductive devices areself-aligned polysilicon gate MOSFETs.
 5. The structure of claim 2wherein said first conductive stripes are wordlines.
 6. The structure ofclaim 5 wherein said means for application of test probes are probe padsformed at the ends of a plurality of wordlines and located over fieldoxide in the periphery of said structure, said plurality of wordlinesnow becoming testable wordlines, by virtue of their having probe pads ateach end, and said testable wordlines further being arranged in groups,each group containing at least three adjacent testable wordlines.
 7. Thestructure of claim 1 further comprising:(a) a first insulative layerover said first conductive stripes; (b) second conductive stripespatterned over said first insulative layer in a layout identical tocorresponding second conductive stripes in said functional sectionpassing, essentially parallel to each other, from one side of saidregion to the other and contacting a silicon active area throughopenings in said first insulative layer; and (c) means for applicationof test probes to said second conductive stripes.
 8. The structure ofclaim 7 wherein said integrated circuit is a DRAM and said functionalsection is a portion of a cell array.
 9. The structure of claim 8wherein said cell array contains between about 50 and 5,000 partiallyprocessed cells.
 10. The structure of claim 8 wherein saidsemiconductive devices are self-aligned polysilicon gate MOSFETs. 11.The structure of claim 8 wherein said second conductive stripes arebitlines.
 12. The structure of claim 11 wherein said means forapplication of test probes are probe pads formed at the ends of aplurality of bitlines and located over said first insulative layer inthe periphery of said structure, said plurality of bitlines now becomingtestable bitlines, by virtue of their having probe pads at each end, andsaid testable bitlines further being arranged in groups, each groupcontaining at least three adjacent testable bitlines.
 13. The structureof claim 11 further comprising:(a) a second insulative layer over saidsecond conductive stripes; (b) storage capacitors formed over saidsecond insulative layer in a layout identical to corresponding storagecapacitors in said functional section, and contacting activesemiconductor regions; (c) a third insulative layer over said storagecapacitors; (d) conductive contacts formed through openings passingthrough said third insulative layer, said second insulative layer, andfirst insulative layer, thereby contacting each end of a plurality offirst conductive stripes; (e) conductive contacts formed throughopenings passing through said third insulative layer and said secondinsulative layer, thereby contacting each end of a plurality of secondconductive stripes; (f) conductive contacts formed through openingspassing through said third insulative layer, thereby contacting an upperplate of said storage capacitors; (g) a conductive contact to saidsilicon substrate; (h) third conductive stripes patterned over saidsecond insulative layer and contacting said conductive contacts; and (i)means for application of test probes to said third conductive stripes.14. The structure of claim 13 wherein said first conductive stripes arewordlines, said second conductive stripes are bitlines, and said thirdconductive stripes are aluminum or an aluminum alloy.
 15. The structureof claim 13 wherein said means for application of test probes are probepads formed at the ends of said third conductive stripes and located inthe periphery of said test structure.
 16. A structure for electricaltesting of bitline contacts during the manufacture of a DRAM cell arraycomprising a contact string having alternate sections of impurity dopedsilicon active areas and conductive stripes connected by bitlinecontacts, said contact string further comprising:(a) a region on asilicon substrate designated for said contact string; (b) a linearsequence of islands of impurity doped silicon active area in saidregion, formed in the framework of said DRAM cell array, and isolatedfrom one another by field isolation; (c) an insulative layer over saidsilicon active area; (d) openings in said insulative layer exposingportions of said islands impurity doped silicon active areas, saidopenings arranged to provide two openings over each island in saidlinear sequence; (e) bitline contacts formed in said openings; (f) aseries of conductive stripes formed in the framework of said DRAM cellarray, over said insulative layer, said conductive stripes lying astrideof said field isolation between said impurity doped silicon active areasand forming a conductive connection between successive islands throughsaid contacts; and (g) means for application of test probes to saidcontact string.
 17. The structure of claim 16 wherein said contactstring contains between 50 and 5,000 bitline contacts.
 18. The structureof claim 16 wherein said means for application of test probes are probepads formed at the ends of said string and located in the periphery ofsaid region.